MEDIUM DUTY CYLINDERS REPAIR MANUAL

Transcription

1 MEDIUM DUTY CYLINDERS REPAIR MANUAL 3/4, 1, 1-1/8, 1-3/8" BORE SERIES A, AV, HV PARTS LISTS REPAIR KITS Makers of and brand Products CAT-

2 CONTENTS PAGE MODEL NOMENCLATURE... 3 PARTS LISTS AND REPAIR KITS Exploded Views of 3/4, 1, 1-1/8" Bore...4 Parts List 3/4, 1, 1-1/8" Bore...5 Exploded View of 1-3/8" Bore...6 Parts List 1-3/8" Bore...7 TROUBLESHOOTING CHART... 8 REPAIR/REBUILDING Series A; 3/4, 1, 1-1/8" Bore Cylinders Series AV; 3/4, 1, 1-1/8" Bore Cylinders...11 Series HV; 3/4, 1, 1-1/8" Bore Cylinders...12 Series AV & HV; 1-3/8" Bore Cylinders TORQUE SPECIFICATIONS - LUBRICATION LIMITATION OF WARRANTY All PHD Products are guaranteed to be free of actual defects in material and workmanship, provided any such defect be reported to PHD in writing within 1 year of shipment from factory. This warranty is limited to replacing or repairing at the Company's option, F.O.B. the Company's factory, any part which, upon Company inspection, is found to have a defect in material and/or workmanship. The Company in no event shall be liable for indirect or consequential damages arising out of the use of PHD Products. Components purchased by the Company from others for inclusion by the Company shall be warranted to the extent set out above and/or to the guaranty or warranty, if any, made by the supplier of said component. APART FROM THE ABOVE EXPRESS WARRANTY, THERE ARE NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. PHD expressly reserves the right to substitute materials in the products described in the catalogs and any supplements thereto: however, this shall not apply to special order products and/or custom products where PHD is advised in writing of specific material requirements and agrees in writing to comply with the request for such specific materials. PHD, Inc. makes no warranty as to the fitness of its products or as to the length of service life after being repaired or parts replaced by anyone other than authorized employees of PHD, Inc. In no event shall PHD, Inc. be liable for loss of profits, in direct, consequential, or incidental damages arising out of the use of PHD and Tom Thumb Products. PHD, Inc. has a policy of continuous product improvement. PHD, Inc. reserves the right to change specifications and designs without notice. 2 Copyright 2012, by PHD, Inc. All Rights Reserved. Printed in the U.S.A.

3 MODEL NOMENCLATURE TO ORDER SPECIFY: Series, Mounting Style, Bore Size, Stroke, Port Control, and any Options (if desired). Also specify rod diameter if non-standard. Rod couplings and mounting attachments must be ordered separately. AV HV A SERIES psi Air psi Hyd psi Air (3/4"- 1-1/8") For use with 1-3/8" bore, Trunnion Mount only. BORE SIZE 3/4" BORE 1/4" Standard Rod Dia. 1/4-28 Thread 1" BORE 5/16" Standard Rod Dia. 5/16-24 Thread 1-1/8" BORE 3/8" Standard Rod Dia. 3/8-24 Thread 1-3/8" BORE 1/2" Standard Rod Dia. 3/8-24 Thread STANDARD STROKE LENGTHS 3/4" BORE 1/4" to 12" 1" BORE 1/4" to 18" 1-1/8" BORE 1/4" to 18" 3/4", 1", & 1-1/8" in 1/4" increments 1-3/8" BORE SIZE 1/2" to 24" in 1/2" increments For Longer Lengths, Consult PHD D DR DC B BR BC CUSHION OR SHOCK PAD - Cushions on both ends - Cushion on rod end - Cushion on cap end - Shock Pads on both ends - Shock Pad on rod end - Shock Pad on cap end (Cushions, Shock Pads, and Spring Return are not available on the same end of cylinder. Shock Pads and 3/4", 1", and 1-1/8" Cushions not available on Series HV.) OVERSIZE ROD To be specified only when using a non-standard diameter. See catalog. SC AV F XI 1 x 2 - P - D 3/8 ROD G-M-V SC SR PROXIMITY SWITCH MOUNTING BRACKETS SERIES BORE AV, HV SPRING RETURN - Spring on cap end - Spring on rod end (Strokes available in 1/4" increments up to 6") and/or DOUBLE ROD END D - Double Rod End Cylinders Leave blank if not needed. 3/4" 1" 1-1/8" 1-3/8" SIZE NO F B R T RF CF **K *L *P **TR RR RC RRC MOUNTING STYLE - Foot Mount, thru hole - Bottom Mount, Tapped holes in head and cap - Rod Mount, Tapped holes on front face of head - Thread Mount, Threaded snout on head (shipped with mounting nut) - Rod End Flange - Cap End Flange - Clevis Mount, cap end - Pilot Mount, Threaded snout and pilot diameter on head (shipped with mounting nut) - Pivot Mount, Pivot on cap - Trunnion Mount - Tierod Mount, Tierods extend out rod end - Tierod Mount, Tierods extend out cap end - Tierod Mount, Tierods extend out both ends *Available on 3/4", 1", and 1-1/8" Bore only **Available on 1-3/8" Bore only PORT CONTROL BUILT-IN METER OUT FLOW CONTROL VALVE P PR PC - Flow control both ends - Flow control on head end - Flow control on cap end NOTES: 1) For double rod cylinders, rod end options will be applied to both ends of cylinder. 2) For double rod cylinders, -_K extension will be applied to one end only (head end/primary mounting end). 3) Option provides additional cylinder flexibility, but may alter the dimensions. OPTIONS A - Stroke Adjustment, 1/2" of adjustment standard (not avail. on Series HV) E - Magnetic Piston for PHD Hall Effect Switches (not available on Series A) F - #1 Rod End, Standard on 3/4", 1", 1-1/8" Bore (See Note 1) G - #2 Rod End, Standard on 1-3/8" Bore (See Note 1) I - #4 Rod End, Female thread on rod (See Note 1) H47 - Rodlok (Rod clamping device installed. Not available with Z1 or on HV. See option page.) (See Note 3) J - #2X Rod End, Twice as long as standard thread (See Note 1) _K - Extra Rod Extension, in 1/8" increments (See Note 2) L - Coarse Thread Rod End (See Note 1) M - Magnetic Piston for PHD Reed Switches (not applicable on Series A) N - Plain Rod End (See Note 1) Q - Port in Position #1 (Must be specified if required with mounting style F on 3/4 to 1-1/8 with F mounting tab on cap end) R - Ports in Position #2 T - Ports in Position #3 ( F mounting tab on cap end on 3/4 to 1-1/8 U - Ports in Position #4 V - Fluoro-Elastomer Seals W - Close Tolerance Stroke, ±.005" stroke length Y - SAE Ports (HV Series Only) 3/4, 1, 1-1/8" Bore Z1 - Electroless Nickel Plate all Ferrous Parts excluding Rod Ends 3

4 MEDIUM DUTY CYLINDERS SERIES A, AV, HV; 3/4, 1, 1-1/8" BORE SHOCK PAD 23 -A CAP SERIES A CUSHION 23 SHOCK PAD SPRING RETURN WITH -P HEAD SERIES AV CUSHION WITHOUT -P HEAD SERIES HV

5 PARTS LIST SERIES A, AV, HV; 3/4, 1, 1-1/8" BORE KEY PART DESCRIPTION 1 Cap 2 Tube 3 Tierod & Nut Assembly 4 Piston & Rod Assembly 5 Head Assembly 6 Seal Retainer 7 Rod Seal 8 Rod Seal Backup (HV only) 9 Rear Bushing (HV only) 10 Bushing Retainer (HV only) 11 Front Bushing 12 Rod Wiper 13 Piston Seal 14 Tube Seal 15 Piston Seal Backup (HV only) 16 Port Control Kit* 17 Cushion Block Assembly Kit** Ball Check Style (2 Cavity): A, AV HV Kit** Check Seal (Single Cavity): A, AV 18 Stop Tube 19 Spring Return Spring 20 Stroke Adjustment Screw 21 Stroke Adjustment Screw Nut 22 Shock Pad Rod End 1/4" dia. 5/16" dia. 3/8" dia. 1/2" dia. 23 Shock Pad Cap End 24 RF or CF Flange 30 Rod End Jam Nut Standard Rod -F, -J -L -G Oversize Rod -F, -J -L -G Spherical End Rod End Cap End NOTE: 3/4" BORE 1" BORE 1-1/8" BORE Full unit description required followed by -H1200 Full unit description required followed by -H1300 Full unit description required followed by -H1410 Full unit description required followed by -H1000 Full unit description required followed by -H x 4348-x 4351-x Sold as part of Repair Kit only x x x Full unit description required followed by -H1700 Full unit description required followed by -H1600 Sold as part of Cap Assembly only Full unit description required followed by -H x 4349-x 4352-x All part numbers listed are for standard units. Options may affect part numbers. Part number suffix (-1) indicates Buna-N seals. Part number suffix (-2) indicates Fluoro-Elastomer seals. * Port Control Kit contains all parts required for one flow control function. ** Cushion Block Kit contains parts for one cushion control function x 4350-x 4353-x REPAIR KITS Full unit description required followed by -H9010 NOTE: Repair kits include all seals and bushings. SEAL KITS Full unit description required followed by -H9000 NOTE: Seal kits include all seals and backup rings. 5

6 MEDIUM DUTY CYLINDERS SERIES AV, HV; 1-3/8" BORE SPRING RETURN CUSHION CUSHION A CAP SHOCK PAD WITH -P HEAD 6

7 PARTS LIST SERIES AV, HV; 1-3/8" BORE KEY PART DESCRIPTION 1 Head 2 Cap 3 Tube 4 Tierod & Nut Assembly 5 Piston & Rod Assembly 6 Rod Retainer Nut 7 Cushion Stud 8 Cushion Retaining Ring 9 Cushion Seal (AV only) 10 Cushion Disc (HV only) 11 Cushion Spring 12 Rod End Stud 30 Piston 31 Rod 13 Rod Bushing 14 Rod Seal Washer 15 Rod Seal 16 Rod Seal Backup Ring (HV only) 17 Rod Wiper 18 Bushing Seal 19 Bushing Seal Backup Ring (HV only) 20 Tube Seal 21 Piston Seal 22 Piston Seal Backup Ring (HV only) 23 Port Control Kit* 24 Cushion Control Kit* 25 Shock Pad Rod End 26 Shock Pad Cap End 27 Stop Tube 28 Spring 29 Stop Tube Guide 35 Rod End Jam Nut -G, -J -F -L 36 Bushing Retainer 37 Stroke Adjustment Screw 38 Stroke Adjustment Nut T Mounting Nut RF or CF Flange Spherical End Cap End Rod End F Mounting Bracket tab for -P caps NOTE: 1/2" ROD 5/8" ROD Full unit description required followed by -H1100 Full unit description required followed by -H1200 Full unit description required followed by -H1300 Full unit description required followed by -H1410 Full unit description required followed by -H1000 Sold as part of Piston & Rod Assembly only Sold as part of Seal Kit or Repair Kit only x x x x Full unit description required followed by -H1700 Full unit description required followed by -H Sold as part of Cap Assembly only Full unit description required followed by -H All part numbers listed are for standard units. Options may affect part numbers. Part number suffix (-1) indicates Buna-N seals. Part number suffix (-2) indicates Fluoro-Elastomer seals. * Port Control Kit and Cushion Control Kit contain all parts required for one flow control function KITS KIT DESCRIPTION 1/2" ROD 5/8" ROD Repair Kit Full unit description required followed by -H9010 Cushion Repair Kit AV HV x x x x Seal Kit Full unit description required followed by -H9000 NOTE: Repair Kit contains parts to repair one cylinder. Cushion Repair Kit includes parts to rebuild one cushion, including internal seals and springs and a Cushion Control Kit. Seal Kit contains all seals, wiper seal, and backup rings. 7

8 TROUBLESHOOTING SERIES A, AV, HV; 3/4, 1, 1-1/8, 1-3/8" BORE The following troubleshooting chart is provided solely to serve as an aid for identifying the cause of a cylinder malfunction that may occur. The chart is divided into three columns: The SYMPTOM column describes the problem/behavior of the cylinder. The PROBABLE CAUSE column identifies possible sources of the problem. The RECOMMENDED ACTION column indicates the procedure/action to correct the problem. NOTE: One of the most common problems causing poor cylinder performance is internal contamination. This is usually caused by Improperly filtered air or oil powering the cylinder or excessive use of thread sealant/thread tape when installing fittings into the cylinder ports. Take Special Care To Prevent The Sealant Or Tape From Entering Into The Cylinder Ports. SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION Air or oil leaking around piston rod. Cut or worn rod seal. Replace cylinder head bushings and rod seal. Scratched, worn, or bent piston rod. Replace piston & rod. Air or oil leaking around ends of cylinder Tierods not tightened to specifications. Tighten tierods to specifications. tube. Cut defective tube seals. Replace tube seals. Pressure spike in a hydraulic unit may have Replace tierod & nut assemblies. stretched tierods. Air or oil leaking around optional Port Retaining nut not tightened to specifications. Tighten retaining nut to specifications. Control, cushion adjustment needles, or ball check retainer. Cut/defective gasket or O-ring seal. Replace gasket or O-ring seal. Air or oil leaking around optional stroke adjustment screw. Loss of power/continuous flow of air or oil evident in exhaust line. Scored/discolored piston rod. Erratic jumping/binding of piston rod during cycling. Self-sealing Hydro-Lok nut not tightened to specifications. Contaminants have collected around sealing portion of Hydro-Lok nut. Seal on nut is cut or defective. Piston seal blow-by caused by: A. Scratched or worn cylinder tube. B. Cut or worn piston seals. Internal lubrication dried out. (Usually due to extended service.) Excessive side load on piston rod. Cylinder not flat. (Head and cap are not square with each other.) Internal lubrication dried out. (Usually due to extended service.) Ball check not seating properly; usually caused by internal contaminants. (Cylinders with optional Port Controls.) Cylinder not flat. (Head and cap not square with each other.) Tighten Hydro-Lok nut to specification. Clean contaminants from sealing area. Replace Hydro-Lok nut. Replace cylinder tube and/or piston seals. Rebuild/overhaul complete cylinder. Decrease weight of load, or support load with external bearing. Flatten cylinder. Rebuild/overhaul complete cylinder. Clean/rebuild ball check assembly. Flatten cylinder. Optional cushions not functioning properly. Cushion seal in cushion block is cut or worn. Replace cushion seal O-ring in cushion block. Optional Port Controls not functioning properly. Piston rod separates from piston or piston rod end breaks off. Cushion seal/disc cut or worn, spring broken or damaged on piston and rod assembly (1-3/8" bore only). Scored cushion nose on piston (3/4, 1, and 1-1/8" Bores). Internal contamination in ball check or adjusting needle cavities.* Internal contamination in adjusting needle cavity or in the ball check cavity which causes the ball check to seat improperly. Excessive end of stroke shock due to: A. Lack of proper shock absorbers B. High cycle speed C. Large load Replace piston and rod assembly. (Sold as assembly from factory.) Replace piston and rod assembly. (Sold as assembly from factory.) Clean/rebuild ball check or adjusting needle assembly. Clean/rebuild adjusting needle or ball check cavities. Install cushions, external shock absorbers, or external stops. Resize cylinder for the application. * All Series A and AV Cylinders; 3/4", 1", and 1/1/8" bore with optional cushions do not contain a ball check assembly. For further information, consult PHD or your local distributor. 8

9 GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER SERIES A; 3/4, 1, 1-1/8" BORE NOTE: The following steps are based on; the cylinder is disassembled, all seals and bushings are removed, and the parts to be reused are properly cleaned and inspected for defects. Reference pages 4 to 7 for replacement parts/repair kits. Series A BUSHING CYLINDER HEAD (Figure 1) 1. Insert Teflon rod wiper (A) all the way down into the cylinder head. 2. Using an arbor press, press front bushing (B) into head until it bottoms out (Caution: Make sure bushing is not crushed or misaligned and rod wiper is not sheared.) 3. Insert rod seal (C) into cavity until it contacts the front bushing. (Note proper direction of the rod seal in the head.) 4. Using an arbor press, press rod seal retainer (D) into head until it is approximately 1/32" from the rod seal. (Do not crush rod seal between front bushing and rod seal retainer.) (B) Front Bushing (A) Rod Wiper (C) Figure 1 (C) Rod Seal (D) Seal Retainer CYLINDER ASSEMBLY (Figure 2) 1. Install piston seal (A) on piston and rod assembly. 2. Install tube seals (B) onto cylinder head and cap. 3. Apply lubricant (see page 16) or equivalent around circumference of piston and piston seal. 4. Insert piston and rod assembly (A) into cylinder tube (B). (Make sure piston seal does not roll over or twist during insertion.) (Figure 3) 5. Apply lubricant (see page 16) or equivalent into the cylinder head cavity, especially the piston rod seal. Also apply lubricant to threads on piston rod end. 6. Gently press piston rod into cylinder head while simultaneously spinning the head. This procedure will avoid cutting the rod seal with the rod end threads. 7. Seat cylinder tube on the head. Place cap on the opposite end making sure both ports are in their proper locations. 8. Install tierods. Snug up all tierods, but do not tighten. 9. With cylinder on a flat surface, use a flattening bar and rubber mallet to flatten cylinder. (Head and cap are squared with each other.) (Figure 4) 10. Perform final torquing of tierods in the proper sequence (Figure 5) to the recommended torque. (See Torque Specifications on page 16.) 11. Apply air to the cylinder. While cycling, check for leakage around rod and tube seals and for piston seal blow-by. 1 4 (A) Piston Seal (B) Tube Seal Figure 2 (A) Piston & Rod (B) Tube Figure Figure 5 Figure 4 9

10 REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS SERIES A; 3/4, 1, 1-1/8" BORE PORT CONTROLS (Figure 6) 1. With ball check and needle assembly removed, flush out cavities and corresponding internal porting in head or cap with appropriate parts cleaners. Using compressed air, blow out cavities to ensure all contaminants are removed. 2. Place a few drops of Rykon 32 oil or equivalent into ball check cavity. Drop steel ball (A) into ball check cavity. Using an appropriate punch, lightly peen the steel ball into the bottom of the cavity. (This procedure ensures correct seating of the steel ball and proper functioning of the ball check assembly.) 3. Place seal (B) onto ball check retainer (C). 4. Place spring (D) into cavity on ball check retainer. 5. Carefully thread the assembly into the cavity and tighten ball check retainer to the recommended torque specifications (See page 16). 6. Check to make sure retainer nut is screwed all the way down on adjusting needle. Place a few drops of Rykon 32 oil, or equivalent, into Port Control needle cavity. Thread needle assembly* (E) into cavity and tighten retaining nut (F) to recommended torque specifications (see page 16). *NOTE: Needle assembly is shipped assembled in Port Control Kit. (D) Spring Figure 6 (A) Piston Seal (E) Needle Assembly* (F) Retaining Nut (B) Ball Check Retainer Seal (C) Ball Check Retainer CUSHION BLOCKS A (Figure 7) 1. For replacement of the ball check and cushion adjusting needle assemblies, follow steps 1 through 6 under Port Controls. 2. Insert cushion seal O-ring (B) into cavity on the cushion block. NOTE: All Series A and AV cylinders 3/4, 1 and 1-1/8" bore with optional cushions do not contain a ball check assembly. For further information, consult Technical Data Bulletin C3. Figure 7 (A) Cushion Block (B) Cushion Seal O-Ring SHOCK PADS (Figure 8) Shock pads rarely need to be replaced, if ever. However, if replacement is necessary, the rod end shock pad is simply a press-fit on the piston rod. Slide the shock pad (A) onto piston rod until it contacts the piston. The cap end shock pad is also a press-fit into the inside diameter of the cylinder tube. Insert the shock pad (B) into the cap end of the tube to a depth of 1/16" from the end of the tube. (A) Rod End Shock Pad (B) Cap End Shock Pad Figure 8 STROKE ADJUSTMENT (Figure 9) Screw the stroke adjustment screw (A) into the threaded cavity of the cylinder cap (B) as shown. Thread the self-sealing nut (C) onto the stroke adjustment screw making sure the seal portion of the nut is toward the cylinder cap. Note: The face of the cap must be clean and free of nicks or scratches. (A) Stroke Adjustment Screw (B) Cylinder Cap (C) Self-Sealing Nut Figure 9 10

11 GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER SERIES AV; 3/4, 1, 1-1/8" BORE NOTE: The following steps are based on; the cylinder is disassembled, all seals and bushings are removed, and the parts to be reused are properly cleaned and inspected for defects. Reference pages 4 to 7 for replacement parts/repair kits. BUSHING CYLINDER HEAD Series AV Detail of Figure 10 (A) Block Vee Piston Seals Follow steps 1 through 4 for Series A on page 9. CYLINDER ASSEMBLY (Figure 10) 1. Install piston seals (A) on piston (B). Note proper direction of piston seals. 2. Follow steps 2 through 11 for Series A on page 9. PORT CONTROLS Follow steps 1 through 6 for Series A on page 10. CUSHION BLOCKS Follow steps 1 and 2 for Series A on page 10. SHOCK PADS SERIES AV; 3/4, 1, 1-1/8" BORE CYLINDERS WITH THE FOLLOWING OPTIONS: Follow step 1 for Series A on page 10. STROKE ADJUSTMENT (B) Piston Figure 10 Follow step 1 for Series A on page 10. (A) Magnetic Band MAGNETIC PISTON (Figure 11) The magnetic band (A) on the piston rarely needs to be replaced. However, if unusual circumstances cause damage to the band, a complete piston and rod assembly with the magnetic band installed must be ordered from the factory. Figure 11 11

12 GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER SERIES HV; 3/4, 1, 1-1/8" BORE NOTE: The following steps are based on; the cylinder is disassembled, all seals and bushings are removed (with the exception of the cylinder head, see below), and the parts to be reused have been properly cleaned and inspected for defects. Reference pages 4 to 7 for replacement parts/repair kits. Series HV BUSHING CYLINDER HEAD Due to the configuration of the double rod seal HV head assembly, the head is available only as a pre-bushed assembly from the factory. (Reference Head Assemblies page 5.) The only exceptions to this are a 3/4" bore with a 3/8" oversize rod, and a 1-1/8" bore with a 1/2" oversize rod. Reference CYLINDER ASSEMBLY (Figure 12) 1. Install piston seals (A) on piston (Note proper direction of piston seals). Install piston seal back-up rings (B) behind piston seals as shown. 2. Follow steps 2 through 10 for Series A on page Apply hydraulic pressure to the cylinder. While cycling, check for leakage around rod and tube seals and for piston seal blow-by. (A) Block-Vee Piston Seals (B) Piston Seal Backup Rings Figure 12 Detail of Figure 12 REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS PORT CONTROLS Follow steps 1 through 6 for Series A on page 10. MAGNETIC PISTON Reference step 1 for Series AV on page 11. SERIES HV; 3/4, 1, 1-1/8" BORE 12

13 GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER SERIES AV & HV; 1-3/8" BORE NOTE: The following steps are based on; the cylinder is disassembled, all seals and bushings are removed, and the parts to be reused are properly cleaned and inspected for defects. Reference pages 4 to 7 for replacement parts/repair kits. BUSHING CYLINDER HEAD Series AV & HV; 1-3/8" Bore 1. Insert rod seal back-up ring (A) (Series HV only) and rod seal (B) into cavity of rod bushing (C) as shown. (Note proper direction of rod seal in bushing, Figure 13.) 2. Install bushing seal back-up ring (D) (Series HV only) and bushing seal (E) onto outside of rod bushing. (Figure 13) 3. Insert rod wiper (F) into bushing retainer (I). (Note proper direction of the rod wiper in the bushing retainer, Figure 13.) 4. Place rod seal washer (G) into bushing cavity in cylinder head (H). (Figure 13) 5. Apply lubricant (see page 16) or equivalent around diameter of bushing seal (E) and inside diameter of Rod Seal (B). Insert rod bushing assembly into head. (Note proper direction of rod bushing assembly into head.) 6. Thread bushing retainer (I) into head and tighten to recommended torque specification. (See Torque Specifications page 16.) Reference I D E C A F B G H Detail of Figure 13 Figure 13 CYLINDER ASSEMBLY 1. Install piston seals (A) on piston. (Note proper direction of piston seals on piston, Figure 14.) Install piston seal back-up rings (B) (Series HV only), behind piston seals as shown (Figure 14). 2. Install tube seals onto cylinder head and cap (Figure 14). 3. Apply lubricant (see page 16) or equivalent around circumference of piston and piston seals. Head C A C Cap B Detail of Figure 14 Figure 14 13

14 GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER (cont.) 4. Insert piston and rod assembly (D) into cylinder tube (E) (Figure 15). Make sure piston seals do not roll over or twist during insertion. 5. Apply lubricant (see page 16) or equivalent into the cylinder head cavity, especially around the piston rod seal. Also apply lubricant to threads on piston rod end. 6. Gently press piston rod into cylinder head while simultaneously spinning the head. This procedure will avoid cutting the rod seal with the rod end threads. 7. Seat cylinder tube on the head. Place cap on the opposite end making sure both ports are in their proper locations. 8. Install tierods. Snug up all tierods but do not tighten. 9. With the cylinder on a flat surface, use a flattening bar and rubber mallet to flatten the cylinder (Figure 16). (Head and cap are squared with each other.) 10. Perform final torquing of tierods in the proper sequence (Figure 17) to the recommended torque. (See Torque Specifications on page 16.) 11. Apply air or hydraulic pressure to the cylinder. While cycling, check for leakage around rod and tube seals and for piston seal blow-by. Figure 15 (A) Piston & Rod Assembly (B) Tube Figure Reference 3 2 SERIES AV & HV; 1-3/8" BORE CYLINDERS PORT CONTROLS (Figure 18) 1. With ball check and needle assembly removed from the head and cap, flush out cavities and corresponding internal porting with appropriate parts cleaners. Using compressed air, blow out cavities to ensure all contaminants are removed. 2. Place a few drops of Rykon 32 oil, or equivalent, into ball check cavity. Drop the steel ball (A) into the ball check cavity. Using an appropriate punch, lightly peen the steel ball into the bottom of the cavity. (This procedure ensures correct seating of the steel ball for proper functioning of the ball check assembly.) 3. Place seal (B) onto ball check retainer (C). 4. Place spring (D) into cavity on ball check retainer. 5. Carefully thread the assembly into the cavity and tighten ball check retainer to the recommended torque specification. (See Torque Specifications on page 16.) 6. Place a few drops of Rykon 32 oil, or equivalent, into Port Control needle cavity. Thread needle assembly*(e) into cavity and tighten retaining nut (F) to recommended torque specification. (See Torque Specifications on page 16.) *Note: Needle assembly is shipped assembled in Port Control Kit. Figure 17 REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS B C Figure 18 D A F E 14

15 CUSHION SERIES AV & HV; 1-3/8" BORE (cont.) For replacement of the cushion adjusting needle in the head or cap, follow step 6, page 10, under Port Controls. NOTE: If cushion malfunction is due to wear or damage of the components on the cushion poppet assembly (A) on the piston and rod assembly (Figure 19), a complete piston and rod assembly must be ordered from the factory. (A) SHOCK PADS (Figure 20) Shock pads (available on Series AV only) rarely need to be replaced, if ever. However, if replacement is necessary, the rod end shock pad is simply a press-fit onto the piston rod. Slide the shock pad (A) onto the piston rod until it contacts the piston. The cap end shock pad is also a press-fit onto a stud located on the piston. Insert the shock pad (B) onto the stud until it contacts the piston. Figure 19 A B Figure 20 STROKE ADJUSTMENT (Figure 21) Screw the stroke adjustment screw (A) (available on Series AV only) into the threaded cavity of the cylinder cap (B) as shown. Thread the self-sealing nut (C) onto the stroke adjustment screw making sure the seal portion of the nut is toward the cylinder cap. Face of cap must be clean and free of nicks or scratches. A B C Figure 21 MAGNETIC PISTON (Figure 22) A The magnetic band (A) on the piston rarely needs to be replaced. However, if unusual circumstances cause damage to the band, a complete piston and rod assembly with the magnetic band installed must be ordered from the factory. Figure 22 15

16 TORQUE TORQUE SPECIFICATIONS TORQUE (in-lb) PART DESCRIPTION 3/4" 1" 1-1/8" 1-3/8" BORE BORE BORE BORE Nut, Tierod Retainer, Ball Check, & NEEDLE (PORT CONTROL & CUSHION) RETAINER, BUSHING 310 ROD, PISTON & DOUBLE ROD STUD, CUSHION 75 STUD, ROD END 140 STUD, ROD END (OVERSIZE) PISTON ROD NUT 200 F MOUNTING BRACKET SCREWS BOLTED ON FLANGE SCREWS BUMPER MOUNTING SCREWS SPHERICAL ROD END NUTS TRUNNION PINS LONG STROKE UNIT MOUNTING SCREWS NUT, TIEROD EXTENSION RR, RC, RRC LUBRICATION SERIES A & AV All air cylinders are permanently lubricated at the factory and can be used for dry air service, if desired. When rebuilding an air cylinder or when lubrication is required due to adverse conditions, PHD recommends the following mixture to be used: 50% STP oil and 50% Amoco Rykon 32 oil (or equivalents). NOTE: This lubricant mixture is also recommended for lubricating the piston and rod seals on hydraulic units units when rebuilding the cylinder. STP is a registered trademark of STP Corporation. Amoco Rykon 32 is a registered trademark of Amoco Oil Company. PHD, Inc Clubridge Drive P.O. Box 9070, Fort Wayne, Indiana U.S.A. Phone (260) Fax (260) phdinfo@phdinc.com PHDinEurope GmbH Arnold-Sommerfeld-Ring Baesweiler, Germany Tel. +49 (0) Fax +49 (0) info@phdineurope.de 16 pdf 2/